sure they are certified to the Indian Boiler Regulations. (IBR). The Indian Boiler Authorities strictly enforce the requirements of IBR, refusing site installation or. Indian boiler regulation act pdf. Free Download e-Books R0 stcvsm stcvsm c windows system32 drivers stcvsm. Kernel Auto Running - C. Windows. This Act may be called the Indian Boilers Act, (2). It extends to the whole "prescribed" means prescribed by regulations or rules made under this Act;. (f).
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Central Boilers Board Examination, Result · Application Form for Competent Person Authorisation Card · Instructions to submit the application for. destined for installation in India must comply with the Indian. Boiler Regulation ( IBR) The IBR is a construction code that includes requirements for design, . Indian Boiler Regulations, These Regulations shall apply to all boilers including those working on principles of natural circulation, forced circulation and .
Plain and Stay Tubes Definition of the Term 'Fusion Weld' Use of Dished Ends Mouthpieces and Doors A. Circularity Classification of Fusion-Welded Boilers Types of Welded Shell Seams Crown Plates and Tube Plates. Manhole Frames. Engraving of Registry Number A. Shells Seatings for Mountings Bar Stays and Firebox Stays Raised Manhole Frames.
Registration Fee Compensation for Openings in Shells End Plates. Girder Sling Stays Foundations of Vertical Boiler Furnaces Uptakes of Vertical Boilers Plain Tubes Furnace Components. Corrugated Fireboxes of Vertical Boilers Girders for Firebox and Combustion Chamber Crowns Revalidation of Certificate etc. Flat Tube Plates and Tubes Nests Gusset Link. Hemispherical Furnaces of Vertical Boilers Brace and Similar Stays Longitudinal Bar Stays Loads on Stay Tubes and Bar Stays Stay Tubes Manhole Openings in Flat Plates Pitch of Tubes Plain Furnaces of Vertical Boilers Foundationsof Locotype Boiler Fireboxes Compression of Tube Plates Stays for Fireboxes and Circular Furnaces Firebox Crown Stays for Locotype Boilers Certificate for Use of an Economiser: Memorandum of Inspection or Registration Book: Inspecting Authorities Certificate of Inspection during Construction: Inspecting Authority Certificate of Inspection during Construction of Boilers for which variations from Standard Conditions have been permitted: Constructor's Certificate of Manufacturer and Test: Certificate of Manufacture and Test: Certificate of manufacture and Test: Certificate of Manufacture and Test of Castings and Forgings: Provisional order under section 9 of the lndian Boilers Act of Certificate for Use of a Boiler: Contractor's Certificate of Manufacture and Test: Memorandum of lnspection or Registration Book-Economisers: Provisional Order under lndian Boilers Act.
Questionnaire to be Answered by. Fittings and Feed Supply Steam Pipes and Connected Fittings: Questionnaire to be Answered by Firms Seeking Recognition bv! JA Appendix. J Appendix. F Appendix. Certificate of Approval for Competent Authority: Certificate of Aooroval for Well-known Steel Maker: Certificate of Approval for Well-known Forge: Certificate of Approval for Well-known Pipe maker: JB Appendix.
E Appendix. A Appendix. Power Utility Boilers: Waste Heat Boilers: Safety Valve Discharge Efficiency Testing: L Annexure II: Diagrams of Riveted Joints with Formulae: Forms of Standard Tensile Test Pieces: Flanses for Pipes. B Appendik. D Appendix. Short title. Transfer of certificates. Powers of entry Report of accidents Appeals to Chief Inspector Appeals to appellate authority Power of Central Government to revise order of appellate authority Finality of orders Minor penalties Penalties for illegal use of boiler Other penalties Penalty for tampering with register mark Limitation and previous sanction for prosecutions Trial of offences Central Boilers Board Power to make regulations Power of Central Government to make rules Power to make rules Penalty for breach of rules Publication of regulations and rules Power of Central Government to give directions Recovery of fees etc.
INDIAN BOILER REGULATIONS
Alteration or renewal of boiler component Duty of owner at examination Production of certificates. Part II. See Gazette of lndia. Section 3. Definitions In these Regulations. Short Title. All DiagramslDawings in this book are not to scale.
In the said Regulations. I f "feed-pipe3'- i: Indian Boiler Regulations c signing and issue of certificates in the relevant. I "State" or "States" means a State or the States to which these regulations extend. ASME Boiler and pressure vessel code. Inspection of Boiler to comply into any Foreign Code Notwithstanding anything contained in these regulations. TEMA with the minimum thickness specified in those codes of manufacture. The decision of lnspecting Authorities shall be binding on all Registering Authorities.
General requirements. Tubes and steam-pipes shall also be inspected at the makers' works at the stages prescribed in Appendix J. In case of Waste Heat Boilers.
In case of a boiler which is to be assembled only at site. The Chief lnspector may. Together with such certificate the lnspecting Authority may furnish a Memorandum of lnspection Book in Form I prepared in the manner prescribed by Regulation in respect of the lnspection of the boiler during construction and the hydraulic test applied on completion. IOOfor General Assembly drawing. I I In case where the original certificate from well-known steel makers in Form IV is not produceable.
In the case of water tube boilers. I 6 Indian Boiler Regulations iii A drawing or print to a scale. The drawing shall show details of riveting of longitudinal and circumferential seams with pitch of rivets.
Provided further that in respect of the steel made and tested by Well-known Steel Makers recognised by the Central Boilers Board in the manner laid down in regulations 4A to 4H. The certificate from the 3 maker of the plates. Provided that where an lnspecting Authority furnished a certificate in Form II together with a Memorandum of Inspection Book in Form I in accordance with sub-regulation c i the certificates prescribed under clauses ii and iv need not be furnished to the Chief Inspector when application is made for registration of the boiler.
For pressure parts. But should any question arise in respect of the fitness of the boilers for the working pressure approved by the lnspecting Authority within a period of three years from the date of their registration. Provided also that in respect of the tubeslpipes made and tested by well-known tubelpipe maker recognised by the Central Boilers Board in the manner as laid down in regulations 4A to 4H.
I iv A certificate in Form IVfrom the steel maker and a certificate from the maker of the plates. Until In addition. Ill the short-term stress-rupture tests for hours as described below are carried out by NMUSteel Plants for the purpose of checking whether the steel is up to the specification and also to ensure that the Steel is capable of meeting the long-term rupture stress valueslmaximum allowable stress values given in ASME or BS or EN Code.
Both the samples should pass hour tests at the above stress and temperature. The samples could be in the form of semi-finished products. These samples may be selected at random by the Chief Inspector of Boilers of the respective State.
At this stress. I a certificate is furnished by the producer of the steel to the effect that the steel has been manufacturedstrictly in accordance with the technical requirements of the ASME or BS or EN Code to assure that the creep rupture requirements are complied with.
Work's Number I tests may be carried out by them and the particulars regarding testing of material including mechanical tests as certified by them shall be noted in the appropriate column or paragraphs in the certificate inForm Ill-B Tested to In case All boilers of capacity less than 20 Tons per hour shall carry all the mountings or fittings certificates in respective forms with details mentioned in Form Ill.
New Delhi. Central Boilers Board. Central Boilers Board shall send a questionnaire in any of the Forms Forms XV-A to XV-G applicable to the area of activity to the applicant who shall send the same after duly completed. Well-known Steel Maker. Well-known Material Testing Laboratory. Well-known FoundrylForge. Two Thousand US Dollars per additional unit shall be deposited.
Application for Recognition 1 An application for recognition as Competent Authority. Ministry of Industry Department of Industrial Development. Well-known Foundry or Forge. The certificate of recognition shall be from the date of the visit of the plant by the Evaluation Cornmittee and shall be for a period of five years.
Central Boilers Board and in case the Liaison Sub-committee decides to refuse recognition. Central Boilers Board shall send all the applications received under subregulation 1 of regulation 4A. Recognition of a Firm as Competent Authority. In the case of renewal of the recognition. Function of Evaluation Committee The Evaluation Committee shall evaluate the performance of a firm applying for recognition in accordance with the provisions of these regulations.
Provided that the firm which has been granted recognition and has not completed a period of three years.
Renewal of Certificate of Recognition a A firm desiring renewal of the certificate of recognition shall apply for such renewal at least three months before the expiry of the validity of the certificate to the Secretary. Appeal 1 Any firm not satisfied with the reasons given by the Liaison Sub-committee for refusing to accord recognition may file an appeal in writing to the Chairman. Inspecting Authority. Indian Boiler Regulations 4D. Certificate of Recognition A certificite of recognition issued under regulation 4C.
Well-known FoundryIForge. Central Boilers Board who after following the procedure laid down in these regulations may renew the certificate of recognition and such renewal shall be valid for a further period of five years.
Provided further that if an application is not made in time. Application for Registration o f Existing Competent Authority etc. All the existing firms recognised as Competent Authority. Validity of. If in such cases the Chief Inspector is clearly satisfied that the material is of good quality. Modification o f Formulae i Under the Regulations for determining the working pressure to be allowed on various parts of boilers.
For iron across the grain the tensile strength may be 18 tons per square inch. Indian Boiler Regulations iv Documentation a lnspection and test procedures. In such cases the values of tensile and shear strength shall not be more than 26 and 21 tons per square inch for steel. Material not fully identified Where the material as for example plate.
Standard specifications for materials The standard specifications for steel wrought iron and copper plates and bars. Registratioh of second-hand boilers not in accordance with the standard conditions If a second-hand boiler is not conforming to the requirements of these regulations for its registration.
Indian Boiler Regulations 13 iii For flat plates of copper. Age of boiler from the date of first use in years Reduction in working pressure percent 25 5 35 10 45 15 50 20 60 30 70 40 80 50 90 60 70 8. Welding a The use of welding in the construction of boilers shall be permitted only where specifically provided for in the standard conditions. Process of Manufacture a 'steel for plates shall be made by the open hearth. Chemical Analysis a The Steel shall not contain more than 0.
For plates having thickness more than 12 mm. The boiler manufacturer may. Testing and lnspecting The following tests and inspections shall be made at the place of manufacture prior to despatch. Schedule of Percentage of Rolling Weight Tolerances for Boiler Plates All the above margins will be taken over nett theoretical weight. Surface defects may be repaired by welding. Rolling Margin No plate or rolled section shall be under the specified thickness at any part. Minor surface defects of the plates may be removed by mechanical means to achieve a smooth level surface provided that the minimum specified thickness is maintained.
Freedom from defects. Where a steel plant is not able to designate steel as IS: If a certificate of test is furnished by the steel makers in respect of tests carried out by them and another certificate is furnished in respect of remaining tests conducted by any one of the independent testing laboratories or the Bharat Heavy Electrical Limited. Such remaining tests may also be conducted at the Bharat Heavy Electricals Limited.
Tiruchirapally in respect of plates intended for their use. Tensile test pieces a The tensile strength and percentage elongation shall be determined from test pieces of gauge See regulation Durgapur or the National Test House.
Alipur or Sewri. Central Mechanical Engineering Research Institute. National Metallurgical Laboratory. Testing and certification of semi-skilled steel for which all tests not carried out in a steel plant Where a steel plant has not been able to carry out all the tests required under the regulations for testing the semi-skilled steel.
If the certificate of tests from steel makers and the National Metallurgical Laboratory. Alipur or Sewri for conducting the remaining test provided that samples are drawn in the presence of the lnspecting Authority. Selection of test pieces All test pieces shall be selected by the lnspecting Officer and tested in his presence. Tiruchirapally in the presence of the lnspecting Authority in respect of plates intended for their use. It is open to the manufacturer to take such steel which has the required potentialities of IS: Indian Boiler Regulations 17 tests which it has not been possible for them to conduct in order to get the steel certified as IS: Wherever practicable.
Tensile test a The tensile strength of different grades of material shall be within the limits specified in regulation 9 d. Table Minimum values for the ratio of the stress at proof limit 0. For plate thickness exceeding 60 mm test pieces shall be taken from the exterior third of the plate cross-section. I I I d The minimum values of the stress at proof limit 0. Tensile strength kg. The test pieces shall not be annealed unless the material from which they are cut is similarly annealed in which case the test piece shall be similarly and simultaneousljl treated with the material before testing.
A dump test shall be made for each Tensile Test. Dump Tests Short lengths equal to twice their diameter cut from the rivet bars shall. Number of Tensile Tests a Plates-For shell plates. For rivets bars bend tests are not required. Bend Tests-Cold bends a Test pieces shall be sheared lengthwise or crosswise from plates or bars. If the unsatisfactory result of a test is obviously due to technical conditions of the testing methor' or to a closely limited defect of a test piece.
Number of Bend Tests a Plates-A bend test shall be taken from each plate as rolled. Following this. Additional test before rejection I 1! I Should the test pieces first selected by the Inspector or lnspecting Officer not fulfil the tesf requirements.
The bend tests from shell plates. Branding I. In all such cases further tests shall be madC before any material from the same charge can be accepted. As an alternative the rivet bars may be bundle and tabbed to enable the material to be traced to the cast of steel from which they are made.
Manufactured Rivets a Quality of Material-Rivets shall be manufactured from steel complying with the aforementioned requirements of this Chapter in respect of rivet bars. I i Every plate. If the unsatisfactory result of test is due to an unfavourable heat treatment the plate and the test strip may bL heat treated again. Name of the manufacturer.
Steel not produced where rolled Where steel is not produced in the works at which it is rolled.. When he is satisfied with the material and with the results of the tests. Maker's Certificate Before the mill sheets are singed. Facilities for Inspection The maker shall adopt a system of making the ingots. Heat No. Defacing of rejected material In the event to the material failing in any case to withstand the prescribed tests. Indian Boiler Regulations 21 ii Every plate shall also be stamped by the steel maker as provided in IS: Plate No.
Rivet Bars The tensile breaking strength shall be between 21 and 25 tons with an elongation of not less than 25 per cent measured on the Standard Test Piece B as rolled or 30 per cent measured on the Standard Test Piece B. The following information shall necessarily be provided: The number of the charge shall be marked on each plate or bar for the purpose of identification.
If either of these is unsatisfactory. The fracture must be clean. E To comply with Regulation F I[ 8 To comply with Regulation 19 Ntimber of Tensile Tests-The bars as rolled shall be placed in batches of twenty. Stay Bars. If this is unsatisfactory. Stay Bars-Bend Tests. The tensile breaking strength. Minimum tensile strength lb. The scrap margin. They shall be thoroughly annealed. If the tensile test is made on a piece of tube.
The tubes shall be finished by cold drawing. A batch shall not consist of more than tubes. The results obtained from a batch shall be uniform. From each bar selected. If the tensile test is made on strip cut from the tube. Not less than Not less than 70 per cent of copper and not more than a total of 0. The test piece shall be flattened down until the interior surfaces of the tube meet and then be double over on itself.
Indian Boiler Regulations g Flanging Test-The test piece shall stand flanging cold see Diagram 3 without showing either crack or flaw until the diameter of the flange measures not less than 40 per cent more than the original diameter of the tube.
The tubes shall withstand the test without showing any signs of weeping of evidence of defects. The tubes shall be straight and unless otherwise ordered they shall be uniform diameter throughout. Indian Boiler Regulations The manufacturer shall supply when required free of charge.
On external diameter k 0. The working margins shall be as follows: The test piece shall be flattened down until the interior surfaces of the tube meet and then be doubled over on itself. The steel shall be fully killed. The tubes shall withstand the test without showing any signs of weeping. Indian Boiler Regulations 27 iii Flattening and Doubling over Test-The test piece shall stand the following test when cold without showing either crack or flaw. The outside diameter at the point of grinding may be reduced by the amount so removed.
Over Finished tubes shall be reasonably straight and have smooth ends free of burrs. They shall have a workmanlike finish. Cold finished seamless tubes Under Surface imperfections like any discontinuity or irregularity found in the tube may be removed by grinding. Outside Diameter mm Hot finished seamless tubes They shall be reasonably straight. These permissible variations in lengths apply to cut lengths up to and including 7. They shall be smooth on the ends and free from burrs and flaws.
Over Under Over 3. For large size tubes. For lengths over 7. Over Over 4. Outside diameter mm 2. Length tolerances on the positive side other than specified may be mutually agreed. Tensile and Hardness Tests The test specimen shall comply with the following requirements.
For longitudinal strip tests a deduction in percentage elongation 1. The hardness test may be carried out on the wall cross section or on a flat on the outside surface of the tube sample. Evidence of laminated or unsound material. If any failure in the tests should occur. Hydraulic test i Each tube shall be tested by the manufacturer and shall withstand a hydraulic pressure to one and half times the design pressure subject to a minimum of 1.
OO kg. If any of these tests fails. Additional test before rejection i If any one or more tests specified in these regulations fail. Expanding or Flaring test A section of the tube approximately mm in length shall stand being flared with a tool having a 60 degree included angle until the tube at the mouth of the flare has been expanded to the percentages given below.
Indian Boiler Regulations 5 When low D-to-t ratio tubular products are tested because the strain imposed due to geometry is unreasonably high on the inside surface at the six and twelve 0' clock location.
Grade PA 0. Pipes manufacturer shall explore a sufficient number of visual inspections to provide reasonable assurance that they have been properly evaluated. Cold drawn pipes shall be given a sub-critical anneal. The pipes shall conform in all respects with the requirements herein specified. For large size pipes. They shall be smooth on ends and free from burrs and flaws. The minimum wall thickness at any point shall not be more than Seamless Hot finished and Cold finished pipes can be ordered in specified length or in random length.
If ordered in specified length. Indian Boiler Regulations i Permissible variations in outside diameter: Hot finished and cold finished seamless pipes - Outside diameter mm Permissible variations mm Over Under The tensile test may be carried out on the test pieces cut out from tl.
If the area thus calculated is more than 4FA. If the calculated area is less than mm2then t I use the actual area thus obtained. Grade Weld Strength MPa kglmm? As an alternative. Indian Boiler Regulations a Tensile test-Test pieces cut from the ends of the selected pipes shall comply with the following requirements. Indian Boiler Regulations ii For pipe whose diameter equals or exceeds mm.
General i These regulations cover both hot finished and cold drawn seamless boiler. Substitution of the bend test for the flattening test shall be subject to the approval of downloadr. If any failure in the tests should occur the entire batch of the pipes shall be rejected. These shall conform in all respects with the requirements herein specified. Additional tests before rejection If any one or more tests specified in these regulations fail. The bend test specimens shall be bent at room temperature through degree without cracking on the outside of the bent portion.
If the repeat tests are satisfactory the pipe shall be accepted. The inside diameter of the bend shall be 25 mm. Hydraulic test i Each pipe shall be tested by the manufacturer and shall withstand a hydraulic pressure to one and half times the design pressure.
Grade Temperature T9 and T22 shall be Degree C. T2 and TI2 either hot finished or cold drawn. If furnished in the normalised and tempered condition. The heat treatment procedure.
Over Under Hot finished Seamless tubes Cold finished Seamless tubes Under If the P grade is hot rolled. Indian Boiler Regulations 37 - iv Grade 12xIM4 shall be normalised at degree C and tempered at degree C for a period of 1 to 3 hours. If cold working is involved in processing. Indian Boiler Regulatir.
Over 3. For grade 12 x IMI 0. Over 4. These permissible variations in length apply to cut length up to and including 7.
O iv 'All specimens shall be tested at room temperature. They shall be smooth on tbends and free from burrs flaws. Indian Boiler Regulatior-.
I ii If desirable and practicable. Indian Boiler Regulations Contd. T22 41 0. Indian Boiler Regulations a Tensile and hardness tests-The test specimen shall comply with the requirements as given in Table 3.
Table 3: Additional tests before rejection i If any one or more tests specified in these regulations fail. Indian Boiler Regulations b Flattening test-A section of the tube not less than 63 mm in length shall be flattened cold between two parallel flat surfaces to a distance between the plates H as calculated by the formula given below.
If any failure in the tests should occur the entire batch of the tubes shall be rejected. Hydraulic test i Each tube shall be tested by the manufacturer and shall withstand a hydraulic pressure to one and a half time the design pressure subject to a minimum of 1. Indian Boiler Regulations Table 4: P2 and PI2 either hot finished or cold drawn may be given a final heat treatment at degree C to degree C.
If furnished in the norrnalised and tempered condition. P9 and P22shall be degreeC. Over iii Permissible variation in length: Over ii Permissible variations in wall thickness: For all grades. For large size pipes the tensile test specimen shall consist of strip cut longitudinally from the pipe and which is not straightened within the gauge length and further heat treated.
I Table 5: Hydraulic test i Each pipe shall be tested by the manufacturer and shall withstand a hydraulic pressure to one and half times the design pressure but not greater than pressure calculated by the following formula given below. A sufficient length of pipe shall stand being bent cold through 90 around a cylindrical mandrel.
Indian Boiler Regulations b Bend test-For pipes of outside diameter The bend test specimens shall be bent at room temperaiure through degree C without cracking on the outside of the bent portion.
A section of the pipe not less than 63 mm is length shall be flattened cold between two parallel flat surfaces to a distance between the plates H as calculated by the formula given below. Substitution of the bend test for the flattening test shall be subject to the approval of the downloadr.
Indian Boiler Regulations where. Over 9 meters 30 ft. Upto and including 9 meters 30 ft. Swelling or reduction shall be carried out before the heat-treatment specified in Regulation 56A iii.
Should the number of tubes specified of any one nominal size exceed The samples for testing shall not be heat treated after selection. Thickness of Tube 3 mm. If the second repeat tests are satisfactory. Flattening test carried out in accordance with any other standard code may be accepted in which case. Should either of the tubes fail in any test. Indian Boiler Regulations 51 vii Flattening test-A ring not less than 51 mm 2 inches in length cut from one end of each selected tube shall be flattened between two parallel flat surfaces.
When the pressure is released. If the repeat tests are satisfactory. In case of cold finished tubes the heat treatment shall be done after the' final cold finishing process. Material c. Provided that ifthe tubes are not hydraulically tested at the pressure required under this regulations. WC1 grade may be fully killed. General a These regulations cover electrically welded tubes made of steel and intended for boiler.
C to Deg. The internal weld upset shall be trimmed throughout the length of the tube so that the maximum height shall not exceed 0.
Note 2: For rimmed or semi-killed steel. The tube shall be well finished and free from harmful defects. The external weld flash shall be removed completely. If rimming steel is used. C either rimming. C shall be of fully killed type. Where the length is specified as exact length or cut length.
No cracks or breaks in the metal shall occur unit the distance between the plates is less than the given by the following formula. Hz- 1te t t etD Where. For every 3 metre increase in length above 6 metres. Evidence of lamination or burnt material or incomplete penetration of the weld shall not develop during the testing.
The steel used for design steam temperature above Deg. When Ladle analysis is not available the analysis of sample tube selected at random may be used. Allowable permissible stress as per the. Hydraulic test I I a Each tube shall be hydraulically tested at the makers' works and shall withstand a hydraulic pressure to one and half times.
The sides of the specimen shall be parallel between gauge marks. If the repeat tests are satisfactory the tubes shall be accepted. Test Specimens a Test specimens required for the flattening and flaring test specified in regulations 59 a and 59 b shall be taken from the ends of finished tubes prior to up setting. Number of tests a The test specified in regulations 59 and 60 shall be made on minimum 2 tubes for first and 1 per or part thereof for tubes over number.
Temperature range Deg. Scope I I a This regulation shall cover carbon steel castings used in the construction of boilers and steam pipes including their fittings. Thickness Outside diameter Plus 7. Tolerance on length shall be in accordance with Regulation 58 f. I vi Hydraulic test-This shall comply with the provision of Regulation WC 3 above. Defects may be repaired by welding only. If the lnspecting Officer does not make such an agreement with the manufacturer. The specified permissible variations in size or thickness shall not be exceeded.
Process of manufacture The steel used for castings shall be made by the Open Hearth or Electric Furnace or any other process which gives steel having equivalent properties. The heat-treatment shall consist of annealing and normalising. Indian Boiler Regulations 57 b For all types of steel castings conforming to these regulations only the minimum values for tensile strength are fixed. Number of test provision of test samples Tensile and bend test pieces shall be prepared from test samples representative of each melt or heat-treatment batch as follows: Freedom from and rectification of defects The steel castings shall have clean surfaces and shall be free from injurious defects.
The discretion of the manufacturer shall not. The steel shall comply with the chemical composition specified in the table above. The agreement for attached test samples shall include the precise location and method of attachment. Test samples shall be stamped by the lnspecting Officer after that heat-treatment process. The samples shall be stamped by the lnspecting Officer so as to identify the castings to which they relate.
Some of the test samples shall be taken from as near the top and others near from the bottom of the casting as is practicable. Indian Boiler Regulations b If the test samples are attached to the castings. The test samples shall be cast in moulds of the same material as is used for the castings and shall be made at the same time as the castings.
Such test samples shall not be detached from the castings until heat-treatment of the castings has been completed and they have been stamped by the lnspecting Officer. Bend tests may be made by pressure or by blows. Should either of the re-tests fail. All the castings shall be fully machined to such an extent that all critical sections are exposed for full thickness. The test pieces shall be bent over the thinner section. If repairs by welding are carried out the castings shall be.
Castings found to be unsound may be treated in accordance with Regulation Inspecting Officer may call for hardness testing of c Non-destructive tests-The lnspechng Officer may call for radiographic examination or other non-destructive testing of the castings. If the welding repairs are sanctioned by the Inspecting Officer. Bend tests Cold bend tests shall be made upon test pieces having rectangular section of one inch wide by inch thick.
Where this further heat treatment is applied. U or V will be governed by i the thickness of the casting.
Indian Boiler Regulation Book-2010, 11th ED Akalank Publications
Pre-heating-Variations in composition. The electrode manufacturer's recommendations for the use of the electrode should be strictly followed. When the later is used. In double preparation. Procedure for welding In order to maintain a high standard of workmanship in the practice of arc-welding to steel castings.
Electrodes for Grades B and C castings should be agreed between the manufacturer and the lnspecting Officer.
Where cracks extend through the section of the casting. Repaired areas of castings shall be reexamined by the lnspecting Officer in accordance with sub-clause i and shall be shown to be free from harmful defects. Surface condition-The surfaces of the steel. The preparation for the welding of cracks should be of the U or V types. U or V the root of the U or V should be sufficiently open to ensure complete penetration.
Castings found to be unsound may be treated in accordance with regulation Stress-relieving treatment-When the welding is carried out after the casting has received its normal heat treatment. When afIer consideration of each casting in the iight of the above variables it is deemed necessary to pre-heat. Electrodes-The electrodes shall comply with Regulations 94 to 98 for Grade A castings. This treatment need be applied only in cases where welding has been such as to induce either internal stresses which would be detrimental to the casting.
In the case of headers for example. For headers with outside diameter less than mm longitudinal test pieces may be allowed. In the case of headers which are closed by special covers. At least one test piece shall be made from each group. The test may be performed also on the semi-finished material for example a bar or a billet. For headers with closed ends. Surface defects may also be repaired.
Selection of test pieces a For testing. In the case of flanges swaged in dies. Indian Boiler Regulations 61 When considering the advisability of applying this further treatment. Similar procedures shall be followed for test pieces of other forgings. Provided that the minimum required thickness is maintained. If the treatment. In the case of headers. Tensile strength Indian Boiler Regulations a The tensile strength of the material shall conform to one of the following four grades: Ultimate tensile stress Tonslsq.
Upto 32 Above 32 and upto 36 Above 36 and upto 38 Internal radius of bend inch I Bend tests may be made by pressure or by blows.
When the bars are cast-on. The test bars shall not be subjected to any heat treatment after leaving the moulds.. All test bars shall be cast in green sand or dry sand or in loam moulds according as to whether the casting or castings they represent are moulded in green sand. Provision of test bars The lnspecting Authority shall state at the time of enquiry whether he requires tensile or transverse tests.
Additional tests before rejection 63 Should either a tensile or a bend test fail. When the test bars are cast separately they shall be poured at the same time and from the same ladle. If the results obtained from these retests are satisfactory.
1. Indian Boiler Regulation-2010 (LATEST)
Dimension of test bars a Transverse Test Bars-The transverse test bars of the diameter specified by the lnspecting Authority according to the main cross-sectional thickness of the casting represented. The number of test bars specified in Regulation 92 shall be applicable to all castings of each melt. If these retests do not give satisfactory results the forgings represented may be re-heattreated together with the remainder of the test blocks and presented for further testings.
In all cases where final retests do not give satisfactory results. Freedom from defects-The castings shall be sound. They shall be well dressed or fettled and shall be machinable by normal methods.
Transverse test A transverse test bar cast in accordance with Regulation 88 a must when placed on suppolts set at the distance shown in column 2 of the following table sustain a load applied at the centre of not less than that shown in column 3 and must show before rupture a deflection not less than that shown in column 4. Bars cast within these limits of diameter may also be machined before the transverse test is made.
For diagram and table see under clause b of this Regulation. Mechanicaltest The casting must comply with the transverse and tensile tests specified in Regulation 90 and Regulation Bars may be tested with either plain or screwed ends. All test pieces shall be selected by the Inspector and tested in his presence and to his satisfaction. Minimum deflection Grade A in. Distance between support in.
Grade A Tons per sq. Tensile test A tensile test bar machined to the dimensions shown in Regulation 88 b and tested with either plain or screwed ends must show a breaking strength of not less than that shown in the following table: Diameter of test bar in.
If the diameter of a transverse test bar as cast varies within the limits specified in Regulation 88 a the equivalent breaking load for the factors given in Appendix F.
Minimum breaking loadGrade A lbs. Size E in. Self-aligning grips to ensure axial loading are recommended. One test for each 4 tons of castings or part thereof. Over 1 cwt. Provided always that in the case of failure of both test pieces if either show obvious defects a thih test piece may be taken from a broken casting or a piece may be cut from a usable casting for furthc 1 testing as follows: The batch or separate casting represented shall be accepted.
C 2nd I The batch or separate casting represented may be rejected. Number of transverse and tensile tests J The number of tests required for each batch of castings shall be in accordance with the followinq I table. Group Weiqht of castinas Upto 28 lbs. G and. One test shall refer I to one transverse and one tensile test. One test for each 2 tons of castings or part thereof. One test for each 4 tons of castings or part thereof or fc each casting weighing 4 tons or more.
I The electrodes shall comply with the requirements of physical tests prescribed for each class. Indian Boiler Regulations :. Note: For pressure parts, assembly drawings of boiler capacity rvMI and above, the scale tobe used is for drum and 1: for General Assembly drawing.
The certificate from the C maker of the plates, rivets or bars, shall show the charge numbers, the plate or bar numbers 0 and the number and dimensions of the various plates etc. But should any question arise in respect! In case where the original certificate from well-known steel makers in Form IV is not produceable, owing to such certificate containing details of plates used for other purposes also, an extract from the original certificate duly signed by the makers of the boiler and countersigned ;'.
Indian Boiler Regulations by the Inspecting Authority shall be acceptable in lieu of the certificate in Form IV, provided all information required in Form IV and furnished in the extract. In addition, certificates in respect of yield point at service temperature 0. Provided that: I a certificate is furnished by the producer of the steel to the effect that the steel has been manufactured strictly in accordance with the technical requirements of the ASME or as or EN Code to assure that the creep rupture requirements are complied with.
II the Steel maker furnishes the necessary certificate that the steel conforms to the chemical analysis, room and elevated temperature mechanical properties given in ASME or BS or EN Code as the case may be. NMUSteel plant to this effect. At this stress, a minimum rupture life of hours is expected.
Both the samples should pass hour tests at the above stress and temperature. These samples may be selected at random by the Chief Inspector of Boilers of the respective State.
The samples could be in the form of semi-finished products, say, forged bars of about 25 mm2 which will undergo heat treatment as prescribed by the relevant specifications. All boilers of capacity less than P Tested to Lbs ,..Furnace Crown a The furnace crown shall be made from one plate and the seam connecting it to the furnace shall not fall in line with any circumferential seam of the boiler shell.
Strength of Riveted Joints Indian Boiler Regulations, These Regulations shall apply to all boilers including those working on principles of natural circulation, forced circulation and forced flow with no fixed steam and water line. Minimum tensile strength lb. Hydraulic test i Each tube shall be tested by the manufacturer and shall withstand a hydraulic pressure to one and a half time the design pressure subject to a minimum of 1.
The samples for testing shall not be heat treated after selection. These shall conform in all respects with the requirements herein specified.
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